"From Clymer Honda XL/XR200-600 1978-1985 printed in December '85. Should be the same as '86 and up.

XL/XR 350-600cc torque specs"

Helpful, thanks! I noticed that the torque specs are just a little lower than the later bikes on several bolts, so that may save me problems with over tightening. I saw a picture somewhere on the XR600 forum that compared an old lower timing gear with a new timing gear. Anyone know where that link is?

Also, I have the case halves reassembled. I'm going to fit the cylinder, piston and head today and then check my timing chain like the earlier link suggested... If it seems off then I'll order a new set. I figure do that before I get too far along. The right side and chain can be assembled any time w/ the cylinder/head on.

"From Clymer Honda XL/XR200-600 1978-1985 printed in December '85. Should be the same as '86 and up.

XL/XR 350-600cc torque specs"

Helpful, thanks! I noticed that the torque specs are just a little lower than the later bikes on several bolts, so that may save me problems with over tightening. I saw a picture somewhere on the XR600 forum that compared an old lower timing gear with a new timing gear. Anyone know where that link is?

Also, I have the case halves reassembled. I'm going to fit the cylinder, piston and head today and then check my timing chain like the earlier link suggested... If it seems off then I'll order a new set. I figure do that before I get too far along. The right side and chain can be assembled any time w/ the cylinder/head on.

As long as I'm spinning the clutch input shaft it seems to shift ok, although sometimes hangs a little by 4th and 5th. If I move the shifter shaft up and down and keep spinning it will shift into those gears. I'm assuming that's because it's not a continuous revolution and the cogs aren't smoothly meshing? I remember having to do that with my other bikes by rocking them back and fourth, engine not running, to get them to shift through the gears so I'm assuming it is a similar issue and not really a problem.

My first 'real' problem: Cylinder bolted on and torqued no probs. Went to install head bolts. Not even up to 'hand tight' and I could feel the rear one near the timing chain spinning. Yep. Stripped threads. Trip to Roseburg! I now have in my possession a M8X1.25 Helicoil Kit, courtesy of O'Reilly Auto. I have enough to do all the threads if it comes to that!

I am using Indian Head Shellac Gasket coating instead of RTV or Copper Spray. I've always had good success with it on these kind of projects.

That's it for now! May go on out to the garage tonight and install a helicoil.

I helicoiled 2 of the headbolts. The other bolt on the right side also decided to let go. Lucky I had a helicoil kit with12 inserts! All torqued to 21 ft/lb.

THEN I put the timing chain on. Yep, definitely stretched... Upper gear looks great. Lower gear has a little wear showing on the teeth, kind of a pattern of streaks from the chain. I guess I'd better start saving for a chain. Anyone have or know of something in a reasonable price range?

Also, I have a lead on a 1987 XL600 that had the cam and lifters go bad. It's going to have to be a trade type deal,
as my budget is limiting out quickly... But, may be my answer to a street legal bike. Parts parts and more parts...

Pro-X seems to be quality. I found one with part number 31.1323 listed as 83-87 XR and XL600's on ebay. However,
It may be NOS as the Pro-X catalog has no listing. Anyone know if this is the right chain? Any other chain part numbers for this bike? I really don't want to spend even more money buying the later chain and sprockets...

Anyone know the D.I.D. part number? how about the Wiseco? Any other brands I'm forgetting?

Pro-X seems to be quality. I found one with part number 31.1323 listed as 83-87 XR and XL600's on ebay. However,
It may be NOS as the Pro-X catalog has no listing. Anyone know if this is the right chain? Any other chain part numbers for this bike? I really don't want to spend even more money buying the later chain and sprockets...

Anyone know the D.I.D. part number? how about the Wiseco? Any other brands I'm forgetting?

thanks,

L

A german site I just discovered is saying that the 31.1323 is a CRF230 (so Ebay is wrong, imagine that!). The chain that fits a 1983-87 XL600 (and I'm assuming that means 86 XR600) is actually 31.1683... Quest continues!

If you were interested in this brand then I'd send them a message through ebay and make sure about the part number they are selling.

The only other option I could think of for finding decent chains is to do the parts search on those other bikes that supposedly have the same timing chain. I'll eventually need another chain for a third engine build I'm planning but I'm not in a hurry to spend money right now either

I probably can afford a 40$ chain, but I'm not really able to swing almost 100$ for a chain right now, just money issues...

I found this part number: 82RH2015-118 which is related to: Regina, Tsubaki, Sudco, Morse and I think Borg-Warner.
This chain fits a bunch of other engines, but I haven't tracked that down yet. Actually this quest is kinda fun...